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Refractories Important Aspects of every Industry

Refractory materials form the most important connection between the thermal process technology and the material to be heated. The functionality is related to the product quality as well as the cost of the heat processes. As we know that refractory materials goes through the best quality standards in critical application areas, such as metal, glass and ceramic production. The most important point of refractory is it must withstand very different thermal, chemical and mechanical loads.  If  the refractory withstand these loads it can produce large number of refractory products such as  refractory and insulation bricks, dense shaped products such as basic, fireclay bricks or silica bricks, kiln furniture, fiber materials.  

For industrial heat treatment, different types of furnaces are used. The selection of the furnace type depends on numerous parameters such as operating then required furnace atmosphere, maximum temperature, loading   and support and transport of the material in the furnace. These are designed especially for each application such as usable volume, heaters, furnace lining and gas etc. Depending on the needs of the furnace user, furnace systems must be planned very flexibly for different products and production volumes or for constant high throughput of large-scale production.

It is true that the world cannot function without Refractories. Refractories are responsible for facilitating many modern manufacturing processes that rely on their robust properties.

The most important characteristic of a refractory is its ability to withstand high temperatures while maintaining dimensional stability after repeated thermal cycling.

Characteristics of Refractories are as follows

·         Abrasion   resistance

·         Bulk   density

·         Cold   crushing strength

·         Creep

·         Melting point

·         Porosity

·         Pyrometric cone equivalent

·         Refractoriness under load

 Global Recycling is one of the topmost rice husk ash manufacturers & suppliers of India. We offer rice hull ash, rice husk ash. We are one of the most reliable and well-known manufacturers of the high-grade Heat insulation compound and ladle covering compounds too. Our products are made of high-quality raw materials. This is the reason why our products contain high insulating power, spread ability, and expandability. Products provided by us spreads quickly and easily to cover the whole surface of the steel. Rice husk has lots of utilities as a tundish covering compound

[ricehusk]

Global Recycling one of the most reliable and well-known manufacturers of the high-grade thermal insulating and covering compounds. Our products are made of high-quality raw materials. This is the reason why our products contain high insulating power, spread ability, and expandability. Products provided by us spreads quickly and easily to cover the whole surface of the steel. Rice husk has lots of utilities as a covering compound. Therefore, it can reduce the heat loss that takes place due to radiation on the steel surface.

[ricehusk]

There are various uses of copper. Copper is used in building construction, power generation transmission, electronic product manufacturing and the production of industrial machinery. Copper wiring and plumbing are integral to the appliances, heating and cooling systems, and telecommunications links used every day in homes and businesses. Copper is an essential component in the motors, wiring, radiators, connectors, brakes, and bearings used in cars and trucks.

[ricehusk]

Global Recycling  is one of the topmost rice husk ash manufacturers & suppliers of India. We offer rice hull ash, rice husk ash. We also deal with heat insulation and tundish covering compounds

[ricehusk]

Cement is manufactured by the combination of calcium, silicon, aluminium, iron and other ingredients. Other common materials used to manufacture cement include limestone, shells, and chalk or marl combined with shale, clay, slate, blast furnace slag, silica sand, and iron ore. The process is these ingredients are heated at high temperatures to form a rock-like substance. Then it’s ground into the fine powder as cement.

[ricehusk]

Global Recycling is one of the topmost producer of rice husk ash. We deal with ladle and  tundish covering compounds and heat insulation compound.

[ricehusk]

Castable Refractories And its Properties

Refractory castables are materials of monolithic kind. It can be mixed with water or any another liquid and formed into definite shapes. They are usually or sometimes held in place by metallic or ceramic anchors. Examples of refractory castables are low cement and ultra-low cement castables, refractory plastics, mortars etc. Self-leveling refractory castables are also available.

They are used in molding shapes and parts at the installation site. Using the refractory bricks has the advantage of operating at the temperatures of the equipment after hydraulic and chemical setting. They are ideal for constructing complete furnace linings and other shapes.

Another definition says that castable is a kind of granular and powdery material made form refractory material with a certain amount of binder. As an amorphous refractory, castable has high fluidity and forms by pouring or spreading. There is some difference with other amorphous Refractories. The differences   are that the refractory castable has a certain setting and hardening time after construction. After finished casting, castable material needs to be removed after a certain period of maintenance, material can be put into drying after a proper time of natural maintenance.

Castable Properties

Simple preparation process, short production cycle and high labor productivity.

It has strong flexibility and is not limited by the shape of industrial kin structure. It can be made into any shape you want.

Good integrity, air tightness and thermal resistance which could reduce the heat loss of the industrial furnace and save the energy as well.

It makes the mechanized construction easy, saving labor and time.

It helps the damaged industrial furnace lining, easy to repair.

Global Recycling is one of the topmost rice husk ash manufacturers & suppliers of India. We offer rice hull ash, rice husk ash. We are one of the most reliable and well-known manufacturers of the high-grade Heat insulation compound and ladle covering compounds too. Our products are made of high-quality raw materials. This is the reason why our products contain high insulating power, spread ability, and expandability. Products provided by us spreads quickly and easily to cover the whole surface of the steel. Rice husk has lots of utilities as a tundish covering compound

[ricehusk]

Our tundish Covering Compound is an insulating powder having good expandability in the Tundish . Tundish Covering Compound is used in ladles tominimize heat loss from the liquid steel.

[ricehusk]

What are refractory materials, Classifications And Types ?

Refractories are inorganic non-metallic material which may withstand heat without undergoing chemical changes while remaining in touch with molten slag, metal and gases.

Refectory may be classified on the basis of

• Chemical composition

• The methods of manufacture

• Their physical forms

 Classification Based on Chemical

Composition

(I) Acid Refractories: Acid refractories are those which are attacked by alkalis (basic slags). These

are utilized in areas where slag and atmosphere are acidic. Examples of acid refractories are:

Silica (SiO2), Zirconia (ZrO2).

(II) Basic Refractories:-

Basic refractories get reacted with acid slags but they don’t react to alkaline slags. Since they do not react with alkaline slags, these refractories are of oxidation can be controlled.

 Classification Based on Physical Form

• Shaped Refractories: These refractories have fixed shaped when delivered to the user. These are what we call bricks. Brick shape can be divided into two: standard shapes and special shapes. Standards shapes have dimension that are conformed to by most refractory manufacturers and are generally applicable to kilns and furnaces of an equivalent type.

Special shapes are specifically made for particular kilns and furnaces. This may not be applicable to another furnaces or kiln of the same type.

 Shaped refractories are nearly always machine pressed, thus, high uniformity in properties are expected. Special shapes are most frequently hand-molded and are expected to exhibit slight variations in properties.

• Unshaped Refractories:

These refractories don’t have a definite form or shapes. They are only given shape upon application. It forms joint less lining and are better referred to as monolithic refractories. These are categorized as Plastic refractories, ramming mixes, gunning mixes

Refractories are classified as dense or insulating types. The most high-temperature refractories, like firebricks, are high-density (>120 lb/ft3). They offer excellent resistance in challenging operating environments, like slags with different chemical compositions, fumes, dust, and gases.

• Insulating refractories have lower densities (4 to 70 lb/ft3) and supply insulating properties, while offering resistance to corrosion and chemical reactions with the operating environment.

 Fire-clay brick Refractories

• Fire-clay brick comprise about 75% of the assembly of refractories on a volume basis and are essentially hydrated aluminum silicates with minor proportions of other minerals.

They are extremely versatile; least costly of all refractory bricks and are extensively used in the iron and steel industry, non ferrous metallurgy, glass industry, cement industry etc.

 Characteristically, fire-clay brick begin to melt far below their fusion temperature and under load actual deformation takes place. The amount of deformation depends upon the load, and, once started, this deformation is a slow but continuous process unless either the load or the temperature is reduced.

 Global Recycling is one of the topmost rice husk ash manufacturers & suppliers of India. We offer rice hull ash, rice husk ash. We are one of the most reliable and well-known manufacturers of the high-grade Heat insulation compound and ladle covering compounds too. Our products are made of high-quality raw materials. This is the reason why our products contain high insulating power, spread ability, and expandability. Products provided by us spreads quickly and easily to cover the whole surface of the steel. Rice husk has lots of utilities as a tundish covering compound

[ricehusk]

Global Recycling one of the most reliable and well-known manufacturers of the high-grade thermal insulating and covering compounds. Our products are made of high-quality raw materials. This is the reason why our products contain high insulating power, spread ability, and expandability. Products provided by us spreads quickly and easily to cover the whole surface of the steel. Rice husk has lots of utilities as a covering compound. Therefore, it can reduce the heat loss that takes place due to radiation on the steel surface.

[ricehusk]

THE PROCESS OF THERMAL INSULATION COMPOUND?

Thermal insulation is that the process of reduction of warmth transfer between objects in thermal contact. These are often achieved with some special process. These special processes will work on suitable object shapes and materials.

Heat flow is an inevitable consequence of contact between objects of various temperatures. Thermal insulation provides a neighborhood of insulation during which thermal conduction is reduced or thermal radiation is reflected instead of absorbed by the lower-temperature body.

 The insulating capability of a cloth is measured because the inverse of thermal conductivity (k). Low thermal conductivity is like high insulating capability (Resistance value). In thermal engineering, other important properties of insulating materials are product density (ρ) and heat capacity

 Heat insulation means preventing the warmth losses from the system. For instance in power plants, the super heated steam is employed drive the turbine so as to supply the facility. The generated super heated steam flows through the pipe which is connected to inlet of the turbine. The pipe through which steam flows that's insulated by wool and aluminum sheet so as to stop the warmth loss. The warmth insulation helps to stop the enthalpy loss within the steam.

Thermal insulation is that the reduction of warmth transfer between objects in thermal contact or in range of radioactive influence. Thermal insulation is often achieved with specially engineered methods or processes, also like suitable object shapes and materials.

 Heat is transferred in three main ways, namely: conduction, convection and radiation.

 Consider the warmth we get from sun a day that's coming through the large space containing no medium in between. Can we insulate earth from that heat? As long as you'll wrap earth with mirror, could also be you'll be ready to reflect a serious portion of radiation heat.

 Now conduction is thanks to transmission of atomic vibration. This needs continuous medium. In metals the warmth is conducted by both free lectrons and lattice vibration. That's why in metals normally electrical conductivity and thermal conductivity are proportional. In non conductors and semiconductors, lattice vibration is that the main carrier. So if you've got a coffee density non conductor having high porosity then certainly that structure material combination will offer you high insulation.

 Convection needs flow of the fluid medium. If you'll create vacuum, you'll get obviate convection.

 So now let's come to your question, rather than answering, let me ask you another question. If you've got a heat source placed at a particular point in space and an object placed near it, then how are you able to stop the foremost of warmth flowing from source thereto object? Well, i might first place a skinny mirror in between the source and object to be protected. Then a skinny layer of vacuum, then a layer of porous rarity non conductor material, hopefully you'll be ready to stop most of the warmth from going from source thereto object.

The reason for giving this lengthy reply is to assist you understand that heat transfer is small more complicated than one might think and that is why best insulator material to be used may vary from application to application.

 Global Recycling is one of the topmost rice husk ash manufacturers & suppliers of India. We offer rice hull ash, rice husk ash. We are one of the most reliable and well-known manufacturers of the high-grade Heat insulation compound and ladle covering compounds too. Our products are made of high-quality raw materials. This is the reason why our products contain high insulating power, spread ability, and expandability. Products provided by us spreads quickly and easily to cover the whole surface of the steel. Rice husk has lots of utilities as a tundish covering compound

[ricehusk]

Synthetic slag Uses

Synthetic slag consists of prepared mixture of several individual oxides which is used during secondary steelmaking to assist the steel treatment in the ladle from the viewpoint of effective refinement.

Uses

New required steel grades need the production of more alloyed, clean and desulphurized steels. This metallurgy demands the use of synthetic slags and slag additives more efficient and complex.

Calcium aluminates

Metallurgical applications

Homogeneous synthetic slags generation

Alternative flux to CaF2

Good protection against H2 /N2/O2 pick up

Capacity of S absorption

High capacity of absorption of steel inclusions

Free Fluorine slags

Addition of MgO in order to reduce refractory wearing

High melting speed

Tipical compositions CaO/Al2O3/MgO

COMPOUND

ALUCAL 40

ALUCAL 55

ALUCAL 55

CaO

40,5 %

35,5 %

26 %

Al2O3

50,5 %

51 %

51 %

SiO2

3,5 %

5,2 %

5,5 %

MgO

3%

4%

10,7%

Fe2O3

1,5 %

1,8 %

2 %

TiO2

1 %

1 %

1 %

Advantages against imported products

Local raw materials, out of abroad markets and currency exchanges.

Possibility to product a wide range of ratios CaO/Al2O3/MgO  according to the process requirements.

Short delivery times, allowing reduce the customers stocks.

Product Presentation: cold agglomerated briquettes.

Slag Fluidizer

Iron losses

Iron losses into desulphurization slag are one of the most important cost factor in hot metal desulphurization process.

Slags generation during desulphurization process and its stirring, causes iron droplets get caught into the slag if it has not fluidity enough.

Slag’s fluidity can be affected by the dissolved carbon incorporated during the process and high melting point slags generation.

The most efficient way to reduce slag’s melting points is by the use of fluxes in the process.

Slag deoxidizer

New applications and steel grades require lower sulfur content, so slags need to be more active in the desulphurization process. It means to have as low as possible oxygen activity.

Source -  http://www.aleastur.com/en/siderurgia-en/synthetic-slag/

Global Recycling is one of the topmost rice husk ash manufacturers & suppliers of India. We offer rice hull ash, rice husk ash. We are one of the most reliable and well-known manufacturers of the high-grade Heat insulation compound and ladle covering compounds too. Our products are made of high-quality raw materials. This is the reason why our products contain high insulating power, spread ability, and expandability. Products provided by us spreads quickly and easily to cover the whole surface of the steel. Rice husk has lots of utilities as a tundish covering compound

[ricehusk]

Global Recycling one of the most reliable and well-known manufacturers of the high-grade thermal insulating and covering compounds. Our products are made of high-quality raw materials. This is the reason why our products contain high insulating power, spread ability, and expandability. Products provided by us spreads quickly and easily to cover the whole surface of the steel. Rice husk has lots of utilities as a covering compound. Therefore, it can reduce the heat loss that takes place due to radiation on the steel surface.

[ricehusk]

Global Recycling one of the most reliable and well-known manufacturers of the high-grade thermal insulating and covering compounds. Our products are made of high-quality raw materials. This is the reason why our products contain high insulating power, spread ability, and expandability. Products provided by us spreads quickly and easily to cover the whole surface of the steel. Rice husk has lots of utilities as a covering compound. Therefore, it can reduce the heat loss that takes place due to radiation on the steel surface.

[ricehusk]

Our tundish Covering Compound is an insulating powder having good expandability in the Tundish . Tundish Covering Compound is used in ladles tominimize heat loss from the liquid steel.

[ricehusk]

How Rice Husk Ash Can be a Replacement Of Portland Cement

The ability and efficiency of using rice husk ash (RHA) to add or partially replace Portland cement in a deep cement mixing technique is investigated. A series of unconfirmed compression tests are conducted on cement-RHA-stabilized clay to investigate the effect of RHA on the mixing properties. Particular attention is paid to its efficiency for increasing strength by partial cement replacement to obtain high-strength clay cement, and is compared to fly ash. The test results indicated that up to 35% of the RHA could be advantageously added to increase strength if the cement content in the mixture exceeded 10%. RHA increases the strength of cement-mixed soil by more than 100% in 28 days. For times of 14 and 28 days, RHA exhibits high efficiency on Portland cement replacement when cement and composite cement content are not less than 20 and 35%, respectively. The optimum condition for high-strength mixing is achieved when 20% cement content of RHA is added to the mixture. When compared with fly ash of similar grain size, the efficiency of RHA is higher when the material to be added is greater than 15%. This indicates the suitability of RHA for use in high-strength clay-cement.

 During the last two decades a large number of researches have been done on the use of waste materials. For the construction industry, the development and use of industrial and agricultural wastes such as fly ash, blast furnace slag, and rice husk ash (RHA). The use of ash by grinding process in cement concrete generally improves the properties of concrete. Ground fly ash or RHA-containing concentrates are of good quality with low porosity and have superior resistance to sulfate attack and chloride penetration as well as high strength. Compared to fly ash which is the most common pozzolan used worldwide in soil stabilization, the use of rice husk ash as a pozolanic material is still relatively low.

 Commercial uses of RHA are in the silica extraction process as pozzolanic material and other applications. Silica is present in amorphous and crystalline forms depending on the temperature and duration of the water. This amorphous silica is highly reactive, especially when it has a good particle size. Since Portland cement requires excessive heat in its manufacture, partial replacement of cement by RHA will result in lower energy consumption and it may be possible to generate certified emission reductions.

 Soil improvement is an alternative method of using this ash. A large amount of research has been conducted on soil stabilization with cement-lime and RHA to evaluate the suitability of these applications, indicating the ability to use RHA to partially replace Portland cement under many circumstances. However, all the above applications are limited to shallow stabilization with low cement content. For deep stabilization, research on the ability to use RHA on Portland cement replacement is very limited. Such application is usually required for the soft ground area from which paddy is produced and biomass power plants are located. Thus, the transport cost of rice husk ash can be reduced, and the feasibility of application becomes more attractive. For the improvement of soft soil by deep cement mixing using mechanical mixing or jet grouting techniques, higher cement content is required because the water-to-cement ratio is a strength-controlled parameter. The increase in specific water content decreases with increasing cement content. The experimental results of previous studies have shown that a sharp increase in strength has occurred from 5% to 25% of the cement content area. Beyond this limit, the effectiveness of increasing the cement content is reduced.

 Global Recycling is one of the topmost rice husk ash manufacturers & suppliers of India. We offer rice hull ash, rice husk ash. We are one of the most reliable and well-known manufacturers of the high-grade Heat insulation compound and ladle covering compounds too. Our products are made of high-quality raw materials. This is the reason why our products contain high insulating power, spread ability, and expandability. Products provided by us spreads quickly and easily to cover the whole surface of the steel. Rice husk has lots of utilities as a tundish covering compound